Jacking Aker

Confidential © 2013 Aker Solutions Preferred partner

Preferred partner

A continuous hydraulic jacking system High Performance Turbine Installation Vessel (HPTIV)

Bergen, 10th Sept. 2013

Roy Martin Edvardsen | Aker Solutions

Product Responsible, Offshore Jacking Systems


Offshore Jacking Systems

OJS Slide 2 13 September 2013

1. Introduction

Link:

Aker Solutions has developed a new concept of a

Jacking System for a Jack-Up vessel for

installation of offshore wind turbines.

■ Using a combination of:

truss legs, and

■ hydraulic pin&hole.

■ A joint-venture agreement with Wartsila, as the

ship designer, a concept of a High Performance

Turbine Installation Vessel (HPTIV) is designed. Jack-Up Leg

Jack-Up Cylinders

Locking Bolt Unit

Main Deck

Tween Deck VESSEL

HULL




2. Success factors and advantage:

■ Truss legs is a more light weighted structure, compared to

■ tubular legs of similar strength for leg sizes approx. 6x6x6 and upwards, - and also easy scalable.

■ For smaller legs than approx. 6x6x6, tubular legs might be more optimal.

Tubular legs: Truss legs:




■ A hydraulic pin&hole system is very reliable, robust, and cost optimal

■ compared to a rack and pinion system, especially for frequent use of

the jacking system. The design is based on the experience from our

drilling technology

■ In this case we have chosen design criteria for jacking to be

280times/year). This is not the case for oil&gas rigs.

Hydraulic cylinders: Rack & Pinion:



OJS Slide 5 13 September, 2013

3. Jacking concept

3.1. Animation HPTIV Animation 2: 8of12 (new)

3.2. Cylinders:

Cylinder sequences : Total 12 cylinders pr leg

■ 4:12 System (Leg Handling, leg up/down)

■ Double speed is then possible compared to 8:12,

decreasing lifting capacity – but we need to lift

“only” the weight of legs.

■ 8:12 System (Jacking, vessel up/down)

2 levels, 2 or 4 cylinders lifting at each corner

■ 12:12 System (Parking)

Increasing system holding capacity with 50%

compared to lifting with 8:12 – giving 48/32*26 717 =

40 106 tons.

6

5

4

3

2

1

12

11

10

9

8

7




3.3. 8:12 System info:

■ By using 8 of 12 cylinders at all times a greater

total lifting force of 33% is then available,

compared to for instance 6 of 12.

■ Cylinder info: ■ cylinder bore Ø550mm

■ rod diameter of Ø330mm

■ 250 bar working pressure

■ 345 bar design pressure

■ => 605tons lifting capacity pr cylinder.

■ => Total lifting capacity of 605x32 =19360 tons.

■ 345 bar is available as capacity for impact loads in

«opposite direction», =345/250*19360 = 26 717 tons,

■ Loads above 345 bar will bleed of with a PSV

(Pressure Safety valve) – protecting the hydraulic

cylinders from pressure above 345 bar.




3.4. RPD: Rack Phase Differential

■ Measuring RPD, is a good indicator of

brace loading for slender truss legs.

■ The HPTIV is designed with a plated

structure in between the chords instead

of braces on the top part of the legs that

are never exposed to wave slamming –

eliminating any RPD issues.




3.5. Footing:

Independent Spud can is chosen, instead of mat footings, having an

advantage to be used on several types of seabed's.

One spike in center of the spud can intended for rocky seabed, and a

large taper surface for medium dense sand (soft soil) around the spike.




3.6. LBU detail:

A specially designed Locking Bolt Unit is designed for

the purpose.

The LBU is transferring the forces between the LEG and

the GUIDING TOWER.




3.7. Chord cross section:

T=140mm

T=100mm




4. HPU : Hydraulic Power Unit

Integrated HPU and hydraulic piping:

■ HPU’s at each leg, no piping in hull

■ 2 HPU’s pr leg is chosen, totally 8.

■ Guiding tower unit to be installed and tested before

installation at yard, reducing fabrication time.

■ One HP system (for working cylinders), and one LP

system (for returning cylinders) + drain line to tank.

■ Main components:

Motor

Oil Tank

Oil cooler

Piping Manifold

Pumps

Control System Cabinet




4.1. Simplified calculation of HPU Power:

Lifting speed: 1.0m/min = 16.67mm/s

Energy = Work / Time = ( Force x Length) / Time

Energy [W] = Force [N] x Speed [m/s], P = F x v

Total HP HPU Power needed:

(incl efficiency 0.6=energy loss in pumps,piping,valves,friction)

P TOT=(19360*1000*10)/0.6x1.0/60)=5.38MW HP Power each leg (2HPU’s):1.34MW (670kW pr HPU)

Assuming 10% LP Power, increasing total

consumption to 1.5 MW pr leg, or 0.75 MW pr HPU, or

375 kW pr motor. If working pressure is increased above working pressure of 250 bar to

achieve extra lifting capacity, then the hydraulic flow (and jacking speed)

needs to be reduced similar.

Energy [W] = Pressure * Flow




4.2. Hydraulic calc. of HPU’s:

Energy = Pressure x Flow, Energy [W] = Pressure [Pa] x Flow [m3/s]

Flow = Speed x Area, Q= v [m/min] x A [m2]

Q in-Lifting =8*Q jacking1.0-piston+4*Q return3.0-rod=8*237+4*456=1896(HP)+1824(LP)=3720l/min. pr. leg

Energy = P/10[bar] x Q*1000/60 [l/min]

Energy HP = 250/10 x (4legs*1896)*1000/60 =3.16 MW

Energy LP = 50/10 x (4legs*1824)*1000/60 =0.62 MW (LP-flow=3xHP-flow) Energy HP+LP = 3.16 + 0.62 = 3.78 MW for the total vessel

Total HPU Power pr. vessel = 5.2 MW pr. Vessel (incl efficiency HP=70%, LP=90%)

Energy VESSEL = 3.16/0.7 + 0.62/0.9 = 4.51+0.69= 5.2 MW Energy LEG = 5.2 / 4 = 1.3 MW pr leg

Energy HPU = 1.3 / 2 = 0.65 MW = 650 kW pr leg

With 2 engines for HPU,

325kW pr motor.

Hydraulic flow diagram,

Cylinders of Test Model 1:6:




4.3. Guiding tower:

■ LBU at each chord, pinned to guiding

tower and

■ guided towards leg chords, removing

horizontal forces between guide tower

and legs.

■ Only VERTICAL forces are therefore

taken by hydraulic cylinders and guiding

tower.




4.4. Guiding tower support structure:

■ Guiding tower are boxed in with a plated

guide tower support structure, taking all

■ HORISONTAL forces at upper and lower

guide points.

■ 2 purposes, weather shield AND strength




5. Maintenance:

Guide support structure will be equipped

with suitable openings to be able to

replace cylinders and HPU pumps/motors

within 24hours.




6. Video film and Test Model 1:6

Link




7. Hydraulic & Control system

Test Model HMI:

A servo valve controls the

hydraulic flow from the HPU to

each side of a pair of jacking

cylinders, (handling 1 LBU).

A pair of locking bolt cylinders is

locking the LBU to the leg with

locking bolts.

The servo valve is controlled by a

servo controller integrated in a

Siemens PLC. (Siemens SIMATIC

Step 7 programming software).

The HMI runs on a Siemens

SIMATIC WinCC Flexible

platform on a panel PC with touch

screen.




Virtual Master curve: (Simplified)

3 LBU*s are «slaves», following a virtual master

time curve, by position. All 3 LBU’s is moved in

vertical direction by 2 hydraulic cylinders.

One LBU is pushing (stroking out) 0%-50% stroke,

Second LBU is pushing (stroking out) 50%-100%,

Third LBU is pulling (stroking in) 100%-0%.




Main Regulating Parameters:

Input parameters are cylinder

pressure (force) and cylinder

absolute position (stroke).

Proximity switches:

Proximity switches reading physical

vertical location of holes in the legs

(when to insert the locking bolt),

and prox’es reading physical

horizontal location if the locking bolt

is inserted in the leg or not (in/out).




Full size vessel, HPTIV

Control center:

• The central Jacking HMI and PLC is located at

the bridge.

• Each leg shall have a setup with also local panels

and PLC on each leg

• A challenge for our system is to handle the

variable direction of load at touch down, when

vessel is going afloat, and cylinders switching

between pull and push !

Redundancy:

Redundancy of E&I hardware and signals will also

be an important part of the setup, having safety as

top priority when doing detailed control system

development for full size vessel with 4 legs.

Control Center




8. HIL-simulation (Hardware-in-the-Loop)

- Real time simulation is used to reduce cost

and failure related to testing of our Jacking

system. We can vary the system algorithm

and easily test the system response with

different parameters – tuning the system to

meet function requirements.

- With Sim-X software we have built a

virtual physical model of the test model

size 1:6, controlled by the PLC developed

for the purpose.

- In workshop we are verifying our virtual

Sim-X model, in order to scale the virtual

system up to a full size HPTIV vessel !

Hydraulic jacking

Cylinders corner1:

Low Pressure

pump:

Locking

Bolt unit1:




9. Operation criteria

■ 1 meter/min jacking speed might not be that important -

because pre-loading is a large portion of the total jacking time. ■ Power consumption is proportional to jacking weight & speed, and must be evaluated up against vessel

- case by case.

■ Hs (Sign. Wave Height) and Tp (Time Period) at specific location (Depth max

50m), defining percentage 1-year operation criteria is more interesting.

■ The HPTIV is designed to operate and install wind turbines in Hs=5, and

if needed, jacking further up to Survival position (18m air gap) in Hs=6,

instead of going to safe location (meaning jacking down and going afloat in Hs=2.5)

that would reduce the operating weather window.

Approx. 70%




10. Global strength analysis

Design conditions: Basic code used is DNV-OS-J301

■ Installation condition (Hs=2.5, Tp max 7sec)

■ Operation condition (Hs=5)

■ Transit condition (Hs=6.5)

■ Survival condition (Hs=10)

Design software:

■ SESAM for package for all linear analyses

■ GTSTRUDL/SELOS for Non-linear dynamic installation analysis

■ TOWER for Time history dynamic analysis based on irregular and random sea




10.1 Survival

Plated field in top of legs requires the

vessel to be jacked up to maximum height

to withstand a SURVIVAL condition.

Self frequency of the system is approx. 8s,

and should preferably be outside 70%

operations of scatter diagram

For Hs= 2.5 Max Tp=7sec




10.2 Installation

DNV-RP-C104 is basis, But GTSTRUDL/SELOS is used for Non-linear dynamic

installation analysis, resulting in a more realistic approach

to the impact loads – and not that conservative.




11. Strengths & weakness (pro’s & con’s)

PRO’s:

■ Reliable and Robust system for frequent jacking (280times/year)

■ Cost optimal and easy scalable for truss legs 6x6x6m-18x18x18m

■ Fabrication friendly, HPU to be fabricated and tested before yard.

■ Operational friendly, to withstand rough weather conditions.

■ Maintenance friendly (24h time limit for critical parts)

■ No fixation system needed

■ Aker Solutions Drilling expertise and mindset in delivery

CON’s:

■ No previous vessels (except one in late 70’s, but no info is available)

delivered with this type of combination.

■ A conservative mindset (=R&P) regarding the choice of jacking system




12. Where are we, and what to do ahead ?

Status of technical solution:

We have established the concept for the mechanical design and

developed a master/slave control philosophy (sequence 8:12) for the

hydraulic system, and executed preliminary tests in workshop of the

same.

Planned work ahead:

More tests are necessary to log and verify the test model up against our

Sim-X simulation , to be able to scale the system doing simulations for

a full size vessel and manipulating the system for worst case scenarios.

This is planned finished by end of Q4 2013




13. Separated Installation and Supply

■ A new concept in addition to HPTIV is developed.

■ J-LASH is one Installation vessel, with several Barges and Tug

boats, for independent Supply of foundation structure, monopiles,

and wind turbines, severe reducing downtime for installation.




14. Marked and planned activities in 2014:

The need of installation vessels is varying a lot and is up to clients !

We need a cooperation with a serious player or client, to continue

further into a basic/detail phase for a specific vessel ?

2013 GL Gerrard Hassan 2012 Douglas Westwood

Indicated 10 – 15 new

installation vessel / year Indicated Overcapacity until

2018 ?




Thank you !


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